SEAT Workshop Service and Repair Manuals

Assembly

–  Place the differential into the clutch casing.   Note! The seal rings must always be replaced. The figure only shows 3 of the 4 bolts with their seal rings. –  Place the main shaft, the secondary shaft and the axle for the reverse gear pinion together. –  Partially tighten the 4 nuts in a cross for the bearing cover for the secondary shaft, finish tightening up to their tightening torque. Tightening torque: 25 Nm + 90º   Note! Clean the remains of the safety agent from the support thread for the reverse gear axle. To do so, use a threaded tap. –  Put the support for the reverse gear axle into place.

–  Assemble the fork for the reverse gear. Position for assembling the axle and the reverse gear fork. –  Assemble the forks together with the connection guides.

–  Screw in a stud bolt -A- M 8 x 100 mm into the support for the reverse gear axle so that it will be aligned after putting the gearbox casing into place. –  Align the connection guides. –  Check that the blocks of the gearbox forks are housed in their respective movable sleeves. –  Check that the magnet is not broken or cracked and put it into its housing in the clutch casing. –  Assemble the gearbox casing over the clutch casing.

–  Screw in the bolts for attaching the clutch casing to the gearbox casing. Tightening torque: 25 Nm + 90º –  Assemble the bolts for the reverse gear axle support -arrow- as stated below: –  Place the bolt -a-, unscrew the stud bolt -A- M 8 x 100 mm - Figure V34-2008 - assemble the bolt -b- and tighten it by hand. Order for tightening: 1.  Bolt -a- 30 Nm 2.  Bolt -b- 30 Nm

–  Assemble the support anchor bolts -arrow- for the gearbox forks. Use a screwdriver to align the connection guides in such a way that each support anchor bolt may be put into its housing. –  Assemble the seal cover for the gear selector axle. Assemble the gear selector axle in the following way: –  Put the connection guides into the position for neutral.

–  Put the boss -arrow 2- onto the gearbox casing trimming. Assemble the gear selector axle so that the connection finger -arrow 1- will fit between the connection guides. –  Screw in the bolts for attaching the gear selector axle to the gearbox casing. Tightening torque: 25 Nm 5th gear pinion Position for assembly:

–  The existing trimming on the inner diameter of the pinion must face towards the gearbox casing.

–  Fit onto the secondary shaft for the 5th gear, using the tool -U-40200/20-. Check for wear on the 5th gear synchroniser ring –  Before the check for wear, clean the synchroniser ring and the 5th gear pinion very carefully

–  Put the synchroniser ring onto the 5th gear pinion. Press the synchroniser ring down over the pinion and measure the gap “a” with a thickness gauge.

Synchronisier ring	Measure “a” on new synchroniser	Limit for wear
5th gear	1.1 … 1.7 mm	0.5 mm

–  Put the 5th gear into place with the needle bearing. –  Put the 5th gear synchroniser ring over the moving pinion. –  Before the assembly, mount the body for the synchroniser/moving body of the 5th gear → Fig.. –  Place the 5th gear pinion on the main shaft.

–  Put the synchroniser ring over the 5th gear pinion. –  Assemble the 5th gear synchroniser unit by carrying out the following steps: –  Place the movable sleeve -2- over the synchroniser bushing -3- so that the trimmings coincide -A- for housing the block pins -4- for both components and that the cogs with pointed ends of the movable sleeve are situated in the same direction as the largest boss -B- of the bushing. –  Assemble the pins for blocking -4- and fit them into place with the springs -1- by offsetting them 120º between each other and under the steps for the blocking pins.

Position for assembling the 5th gear synchronised/movable body –  Put the 5th gear pinion into the main shaft in such a way that the pointed cogs of the movable pinion -arrow 1- and the high collar of the synchronised body -arrow 2- face towards the gearbox casing. –  The housings for the synchronising body -arrow 3- are aligned with the block parts of the synchronised ring.

5th gear synchronised ring with blocking parts built in -arrow-

–  Fit in the movable sleeve set and synchroniser bushing onto the 5th gear pinion. Use the tool -U-40200/20-.   Note! When fitting the movable sleeve unit and synchroniser bushing onto the 5th gear pinion, check that the 5th gear synchroniser ring can turn freely. –  Partially screw in the bolts for attaching the synchroniser bushing and the 5th gear pinion.

Position for assembly –  The concave side of the plate springs -arrow- must be facing towards the synchroniser bushing and the 5th gear pinion.

Before tightening the bolts attach the synchroniser bushing and the 5th gear pinion -arrows- two gears must be connected → Anchor. The primary and secondary shafts are blocked since two gears are engaged; the synchroniser bushing and the 5th gear pinion do not turn. Tighten the bolts -A- . Tightening torque: 80 Nm –  Assemble the connection fork for 5th gear.

Adjust the movable sleeve and the fork for the 5th gear –  Engage the 5th gear and untighten the bolt -1- Press the movable sleeve in the direction of the arrow, then tighten the bolt -1-. Tightening torque: 25 Nm   Note! Between the movable sleeve and the moving pinion, there cannot be a gap of over 0.15 mm. If necessary, repeat the adjustment process. –  Disengage the 5th gear. The movable ring must be placed in neutral, the ring synchronised in this must position must be able to turn freely. –  Check whether all the gears can be engaged easily.

–  Put the seal for the gearbox casing cover into place -arrow-. –  Tighten the bolts for attaching the gearbox casing cover. Tightening torque: 10 Nm –  Assemble the guide sleeve for the clutch release bearing and attach it to the casing with the three lag bolts → Chapter. Tightening torque: 20 Nm

–  Assemble the thrust washers, the springs, the tapered rings and the coupling flanges.